ADC AD-200 User Manual
AD-200 Phase 7
Non-Tilt
Service Manual
American Dryer Corporation
88 Currant Road
Fall River, MA 02720-4781
Telephone: (508) 678-9000 / Fax: (508) 678-9447
E-mail: techsupport@amdry.com
050801DMG/calbert ADC Part No. 450034
www.amdry.com
Retain This Manual In A Safe Place For Future Reference
American Dryer Corporation products embody advanced concepts in engineering, design, and safety. If this product is
properly maintained, it will provide many years of safe, efficient, and trouble-free operation.
ONLY qualified technicians should service this equipment.
OBSERVE ALL SAFETY PRECAUTIONS displayed on the equipment or specified in the installation manual included with
the dryer.
The following “FOR YOUR SAFETY ” caution must be posted near the dryer in a prominent location.
FOR YOUR SAFETY
Do not store or use gasoline or
other flammable vapors or liquids
in the vicinity of this or any other
appliance.
We have tried to make this manual as complete as possible and hope you will find it useful. ADC reserves the right to make
changes from time to time, without notice or obligation, in prices, specifications, colors, and material, and to change or
discontinue models.
POUR VOTRE SÉCURITÉ
Ne pas entreposer ni utiliser d’essence
ni d’autres vapeurs ou liquides
inflammables dans le voisinage de cet
appareil ou de yout autre appareil.
Important
For your convenience, log the following information:
DATE OF PURCHASE ____________________________ MODEL NO. __________________________________________
RESELLER’S NAME _______________________________________________________________________________________
Serial Number(s) ________________________________________________________________________________________
________________________________________________________________________________________
AD-200 Phase 7 Non-Tilt
________________________________________________________________________________________
Replacement parts can be obtained from your reseller or the ADC factory. When ordering replacement parts from the factory,
you can FAX your order to ADC at (508) 678-9447 or telephone your order directly to the ADC Parts Department at (508)
678-9000. Please specify the dryer model number and serial number in addition to the description and part number, so that
your order is processed accurately and promptly.
The illustrations on the following pages may not depict your particular dryer exactly. The illustrations are a composite of the
various dryer models. Be sure to check the descriptions of the parts thoroughly before ordering.
“IMPORTANT NOTE TO PURCHASER”
Information must be obtained from your local gas supplier on the instructions
to be followed if the user smells gas. These instructions must be posted in a
prominent location near the dryer.
IMPORTANT
YOU MUST DISCONNECT AND LOCKOUT THE ELECTRIC
SUPPLY AND THE GAS SUPPLY OR THE STEAM SUPPLY BEFORE ANY
COVERS OR GUARDS ARE REMOVED FROM THE MACHINE TO
ALLOW ACCESS FOR CLEANING, ADJUSTING, INSTALLATION, OR
TESTING OF ANY EQUIPMENT PER OSHA (Occupational Safety and Health
Administration) STANDARDS.
FOR YOUR SAFETY
DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE
VAPOR AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER
APPLIANCE .
DO NOT DRY MOP HEADS IN THE DRYER.
DO NOT USE DRYER IN THE PRESENCE OF DRY CLEANING FUMES.
CAUTION
DRYERS SHOULD NEVER BE LEFT UNATTENDED WHILE IN
OPERATION.
WARNING
CHILDREN SHOULD NOT BE ALLOWED TO PLAY ON OR NEAR
THE DRYERS.
CHILDREN SHOULD BE SUPERVISED IF NEAR DRYER(S) IN
OPERATION.
WARNING
The dryer must never be operated with any of the back guards, outer tops,
or service panels removed. PERSONAL INJURY OR FIRE COULD
RESULT.
WARNING
DRYER MUST NEVER BE OPERATED WITHOUT THE LINT
FILTER OR SCREEN IN PLACE, EVEN IF AN EXTERNAL LINT
COLLECTION SYSTEM IS USED.
IMPORTANT
PLEASE OBSERVE ALL SAFETY PRECAUTIONS displayed on the
equipment and specified in the installation manual included with the dryer.
The wiring diagram for the dryer is located in the front electrical control box area.
Table of Contents
AD-200 REFERENCE GUIDE (Basket [Tumbler] Section) ..............................3
AD-200 REFERENCE GUIDE (Base Section)...................................................4
SECTION I
SAFETY PRECAUTIONS...................................................................................5
SECTION II
ROUTINE MAINTENANCE ..............................................................................7
A. Cleaning ..................................................................................................................................... 7
B. Lubrication ................................................................................................................................. 9
C. Adjustments ............................................................................................................................. 10
SECTION III
SPECIFICATIONS AND DIMENSIONS ......................................................... 11
A. Specifications (Gas and Steam Models) .....................................................................................11
B. Dimensions ............................................................................................................................... 12
SECTION IV
INSTALLATION REQUIREMENTS ...............................................................13
A. Enclosure/Air Supply/Exhaust Requirements .............................................................................. 13
B. Electrical and Gas Requirements ............................................................................................... 14
C. Operational Service Check Procedure ...................................................................................... 14
SECTION V
COMPONENT DESCRIPTION/REPLACEMENT ........................................15
A. Heat Section............................................................................................................................. 15
B. Troubleshooting The Direct Spark Ignition (DSI) System ........................................................... 21
C. Natural Gas and Liquid Propane (L.P.) Gas Conversion Instructions .......................................... 38
D. Steam Coil System Operation ................................................................................................... 39
E. Sprinkler System Description .................................................................................................... 44
F. Air Jet Assembly....................................................................................................................... 50
G. Blower (Squirrel Cage Fan) Motor Assembly ............................................................................ 52
H. Filter/Regulator Assembly ......................................................................................................... 59
I. Door Systems ........................................................................................................................... 60
J. Control and Electrical System ................................................................................................... 65
K. Basket (Tumbler) System.......................................................................................................... 76
SECTION VI
PROCEDURE FOR FUNCTIONAL CHECK
OF REPLACEMENT COMPONENTS ...........................................................86
SECTION VII
PHASE 7 OPL SYSTEM DIAGNOSTICS .......................................................88
A. Diagnostic (L.E.D. Display) Fault Messages............................................................................... 88
B. I/O Board Input and Output L.E.D. Indicators .......................................................................... 90
SECTION VIII
TROUBLESHOOTING.....................................................................................95
AD-200 Reference Guide
(Basket [Tumbler] Section)
3
AD-200 Reference Guide
(Base Section)
4
SECTION I
SAFETY PRECAUTIONS
CAUTION: The dryer should never be left unattended while in operation.
WARNING: For your safety, the information in this manual must be followed to minimize the risk of
fire or explosion or to prevent property damage, personal injury, or loss of life.
WARNING: The dryer must never be operated with any of the back guards, outer tops, or
service panels removed. PERSONAL INJURY OR FIRE COULD RESULT.
1. DO NOT store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other
appliance.
2. Purchaser/user should consult the local gas supplier for proper instructions to be followed in the event the
user smells gas. The instructions should be posted in a prominent location.
3. WHAT TO DO IF YOU SMELL GAS...
a. DO NOT try to light any appliance.
b. DO NOT touch any electrical switch.
c. DO NOT use any phone in your building.
d. Clear the room, building, or area of ALL occupants.
e. Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
f. If you cannot reach your gas supplier, call the fire department.
4. Installation and service must be performed by a qualified installer, service agency, or gas supplier.
5. Dryer(s) must be exhausted to the outdoors.
6. Although ADC produces a very versatile dryer, there are some articles that, due to fabric composition or
cleaning method, should not be dried in it.
WARNING: Dry only water washed fabrics. DO NOT dry articles spotted or washed in dry
cleaning solvents, a combustible detergent, or “all purpose” cleaner.
EXPLOSION COULD RESULT.
WARNING: DO NOT dry rags or articles coated or contaminated with gasoline, kerosene, oil, paint,
or wax.
EXPLOSION COULD RESULT.
5
WARNING: DO NOT dry mop heads. Contamination by wax or flammable solvents will create a
fire hazard.
WARNING: DO NOT use heat for drying articles that contain plastic, foam, sponge rubber, or
similarly textured rubber materials. Drying in a heated basket (tumbler) may damage
plastics or rubber and may be a fire hazard.
7. A program should be established for the inspection and cleaning of lint in the burner area, exhaust ductwork,
and area around the back of the dryer. The frequency of inspection and cleaning can best be determined
from experience at each location.
WARNING: The collection of lint in the burner area and exhaust ductwork can create a potential fire
hazard.
8. For personal safety, the dryer must be electrically grounded in accordance with local codes and/or the
National Electrical Code ANSI/NFPA NO. 70-LATEST EDITION or in Canada, the Canadian Electrical
Codes Parts 1 & 2 CSA C22.1-1990 or LATEST EDITION.
NOTE: Failure to do so will VOID THE WARRANTY.
9. UNDER NO CIRCUMSTANCES should the dryer door switches, lint drawer switch, or heat safety
circuit ever be disabled.
WARNING: PERSONAL INJURY OR FIRE COULD RESULT.
10. This dryer is not to be used in the presence of dry cleaning solvents or fumes.
11. Remove articles from the dryer as soon as the drying cycle has been completed.
WARNING: Articles left in the dryer after the drying and cooling cycles have been completed can
create a fire hazard.
12. READ AND FOLLOW ALL CAUTION AND DIRECTION LABELS ATTACHED TO THE
DRYER.
WARNING: YOU MUST DISCONNECT AND LOCKOUT THE ELECTRIC SUPPLY AND
THE GAS SUPPLY OR THE STEAM SUPPLY BEFORE ANY COVERS OR
GUARDS ARE REMOVED FROM THE MACHINE TO ALLOW ACCESS
FOR CLEANING , ADJUSTING, INSTALLATION, OR TESTING OF ANY
EQUIPMENT PER OSHA (Occupational Safety and Health Administration)
STANDARDS.
IMPORTANT: Label ALL wires prior to disconnection when servicing the microprocessor controller
(computer) and the ignition module. WIRING ERRORS CAN CAUSE
IMPROPER AND DANGEROUS OPERATION.
6
SECTION II
ROUTINE MAINTENANCE
A. CLEANING
A schedule should be established for periodic inspection, cleaning, and removal of lint from various areas of the
dryer, as well as throughout the ductwork system. The frequency of cleaning can best be determined from
experience at each location. Maximum operating efficiency is dependent upon proper air circulation. The
accumulation of lint can restrict this airflow. If the guidelines in this section are met, an ADC dryer will provide
many years of efficient, trouble free, and most importantly safe operation.
WARNING: LINT FROM MOST FABRICS IS HIGHLY COMBUSTIBLE. THE
ACCUMULATION OF LINT CAN CREATE A POTENTIAL FIRE HAZARD.
WARNING: KEEP DRYER AREA CLEAR AND FREE FROM COMBUSTIBLE
MATERIALS, GASOLINE, AND OTHER FLAMMABLE VAPORS AND
LIQUIDS.
NOTE: REMOVE POWER FROM THE DRYER BEFORE PERFORMING ANY
MAINTENANCE IN THE DRYER.
NOTE: Suggested time intervals shown are for average usage, which is considered six (6) to eight (8)
operational (running) hours per day.
SUGGESTED CLEANING SCHEDULE
EVERY THIRD OR FOURTH LOAD
Clean the lint screen. A clogged lint screen will cause poor dryer performance. The lint screen is located in the
lint drawer in the base of the dryer. Pull out the lint drawer, brush the lint off the lint screen, and remove the lint.
Inspect the lint screen and replace if torn.
NOTE: The frequency of cleaning the lint screens can best be determined from experience at each
location.
WEEKLY
Open the hinged panels on each side of the basket (tumbler) section and remove any lint accumulation from the
basket (tumbler) drive motor, drive shafts, gear (speed) reducer, drive belts, drive wheels, and drive shaft bearings.
Slide the lint basket ALL the way out of the dryer and clean any lint accumulation off the temperature sensor
bracket, which is located above the lint basket.
7
WARNING: TO AVOID THE HAZARD OF ELECTRICAL SHOCK, DISCONTINUE
ELECTRICAL SUPPLY TO THE DRYER.
MONTHLY
Empty the compressed air filter bowl.
NOTE: REGULATOR PRESSURE IS TO BE SET
AT 80 PSI (5.51 BARS).
Clean any lint accumulation from the gas valve and burner area
at the top of the dryer, the fan (squirrel cage fan) motor, and
the fan (squirrel cage fan) bearings located in the dryer base.
EVERY 6 MONTHS
STEAM MODELS - Clean the steam coil fins. We suggest
using compressed air and a vacuum cleaner with brush
attachment.
NOTE: When cleaning steam coil fins, be careful not to bend the fins. If fins are bent, straighten by
using a fin comb, which is available from any local air conditioning supply house.
Inspect and remove any lint accumulation in customer furnished exhaust ductwork system and from the dryer’s
internal exhaust ducting.
NOTE: THE ACCUMULATION OF LINT IN THE EXHAUST DUCTWORK CAN
CREATE A POTENTIAL FIRE HAZARD.
NOTE: DO NOT OBSTRUCT THE FLOW OF COMBUSTION AND VENTILATION AIR.
CHECK CUSTOMER FURNISHED BACK DRAFT DAMPERS IN THE EXHAUST
DUCTWORK. INSPECT AND REMOVE ANY LINT ACCUMULATION, WHICH
CAN CAUSE THE DAMPER TO BIND OR STICK.
NOTE: When cleaning the dryer cabinets, avoid using harsh abrasives. A product intended for the
cleaning of appliances is recommended.
Clean off any lint accumulation on top of the temperature probe and the hi-limit switch located above the lint
basket.
8
B. LUBRICATION
MONTHLY
The two (2) bearings that support the squirrel cage fan shaft must be lubricated. Use Shell Alvania #2 grease or
its equivalent. Generically, this grease would be described as an NLGI Grade 2 multipurpose industrial grease
with a lithium thickener and mineral base oil.
EVERY 3 MONTHS
The four (4) bearings that support the drive and idler shafts must be lubricated. Use Shell Alvania #2 grease or
its equivalent. Generically, this grease would be described as an NLGI Grade 2 multipurpose industrial grease
with a lithium thickener and mineral base oil.
9
EVERY 6 MONTHS
Change gear oil in basket (tumbler) shaft gear (speed) reducer.
1. Remove the drain plug (located at the bottom rear of the reducer).
2. After oil is completely drained, replace the drain plug.
3. Remove the vent plug and pour in 1.4 liters of Mobil Oil DTE HH5G (I.S.O. viscosity grade 460), SAE 90,
or its equivalent.
C. ADJUSTMENTS
7 DAYS AFTER INSTALLATION AND EVERY 6 MONTHS THEREAFTER
Inspect bolts, nuts, screws, (bearing setscrews), grounding connecitons, and nonpermanent gas connections
(unions, shutoff valves, and orifices). Fan (squirrel cage fan) V-belts, along with the motor and drive belts should
be examined and replaced if necessary. Tighten loose V-belts when necessary. Complete operational check of
controls and valves. Complete operational check of ALL safety devices (i.e., door switches, lint drawer switch,
sail switch, burner, and hi-limit thermostats).
10
SECTION III
SPECIFICATIONS AND DIMENSIONS
A. SPECIFICATIONS (GAS AND STEAM MODELS)
MAXIMUM CAPACITY (DRY WEIGHT) 200 lbs 90.9 kg
BASKET (TUMBLER) DIAMETER 62-1/2” 158.75 cm
BASKET (TUMBLER) DEPTH 42” 106.7 cm
BASKET (TUMBLER) VOLUME 74.5 cu.ft. 2.11 cu.m.
DRIVE MOTOR 3 HP 2.24 kw
BLOWER MOTOR (GAS/STEAM) 7-1/2 HP/15 HP 5.6 kw/11.2 kw
DOOR OPENING 36-3/4” WIDE x 43” HIGH 93.3 cm x 109.2 cm
DOOR SILL HEIGHT - LEVEL 37-1/4” 94.6 cm
COMPRESSED AIR 80 PSI 5.51 bars
COMPRESSED AIR CONNECTION 3/8” F.P.T.
VOLTAGE AVAILABLE 208-460v 3ø 3, 4w 50/60 Hz
HEAT INPUT 750,000 btu/hr 189,000 kcal/hr
APPROX. WEIGHT (UNCRATED) 3,369 lbs 1,528 kg
AIRFLOW 5,300 cfm 150 cmm
Gas*Steam*
INLET PIPE SIZE 1-1/4”
VOLTAGE AVAILABLE 208-460v 3ø 3, 4w 50/60 Hz
APPROX. WEIGHT (UNCRATED) 3,719 lbs 1,687 kg
AIRFLOW 6,500 cfm 184 cmm
STEAM CONSUMPTION
890 lbs/hr 404.5 kg/hr 27
OPERATING STEAM PRESSURE STEAM SUPPLY STEAM RETURN
125 PSI max 8.61 bars 1-1/2” 3/4”
Shaded areas are stated in metric equivalents
* Dryer must be provided with a clean, dry, regulated 80 PSI +/- 10 PSI (5.51 bars +/- 0.68 bars) air supply
(equivalent volume = 9 cfh [0.26 cmh]).
BOILER HP
NORMAL LOAD
NOTE: ADC reserves the right to make changes in specifications at any time without notice or
obligation.
11
B. DIMENSIONS
NOTE: ADC reserves the right to make changes in specifications at any time without notice or
obligation.
12
SECTION IV
INST ALLATION REQUIREMENTS
Installation should be performed by competent technicians in accordance with local and state codes. In the
absence of these codes, the installation must conform to applicable American National Standards: ANSI Z223.1LATEST EDITION (National Fuel Gas Code) or ANSI/NFPA NO. 70-LATEST EDITION (National Electrical
Code) or in Canada, the installation must conform to applicable Canadian Standards: CAN/CGA-B149.1-M91
(Natural Gas) or CAN/CGA-B149.2-M91 (Liquid Propane [L.P.] Gas) or LATEST EDITION (for General
Installation and Gas Plumbing) or Canadian Electrical Codes Parts 1 & 2 CSA C22.1-1990 or LATEST EDITION
(for Electrical Connections).
A. ENCLOSURE/AIR SUPPLY/EXHAUST REQUIREMENTS
NOTE: The following information is very brief and general. For detailed description, refer to the
AD-200 Phase 7 Non-Tilting Installation/Operator’s Manual (ADC Part No. 112142)
included with the dryer.
Bulkheads and partitions around the dryer should be made of noncombustible materials. Allowances should be
made for the opening and closing of the control door and lint door. Also, allowances should be made in the rear
for ease of maintenance. (Refer to the AD-200 Phase 7 Non-Tilting Installation/Operator’s Manual [ADC Part
No. 112142] for recommended distances and minimum allowances required.)
When the dryer is operating, it draws in room air, heats it, passes this air through the basket (tumbler), and
exhausts it out of the building. Therefore, the room air must be continually replenished from the outdoors. If the
make-up air is inadequate, drying time and drying efficiency will be adversely affected. Ignition problems and sail
switch “fluttering” problems on gas dryers may result, and you could have premature motor failure from overheating.
The air supply must be given careful consideration to insure proper performance of each dryer.
IMPORTANT: Make-up air must be provided from a source free of dry cleaning fumes. Make-up
air that is contaminated by dry cleaning fumes will result in irreparable damage to
motors and other dryer components.
Exhaust ductwork should be designed and installed by a competent technician. Improperly sized ductwork will
create excessive back pressure which will result in slow drying, increased use of energy, and shutdown of the
burner by the airflow (sail) switch, burner hi-limit or lint chamber hi-heat protector thermostat. (Refer to the
AD-200 Phase 7 Non-Tilting Installation/Operator’s Manual [ADC Part No. 112142] for more details.)
CAUTION: IMPROPERLY SIZED OR INSTALLED EXHAUST DUCTWORK CAN
CREATE A POTENTIAL FIRE HAZARD.
13
B. ELECTRICAL AND GAS REQUIREMENTS
It is your responsibility to have ALL electrical connections made by a properly licensed and competent electrician
to assure that the electrical installation is adequate and conforms to local and state regulations or codes. In the
absence of such codes, ALL electrical connections, materials, and workmanship must conform to the applicable
requirements of the National Electrical Code ANSI/NFPA NO. 70-LATEST EDITION or in Canada, the Canadian
Electrical Codes Parts 1 & 2 CSA C22.1-1990 or LATEST EDITION.
IMPORTANT: Failure to comply with these codes or ordinances and/or the requirements stipulated
in this manual can result in personal injury or component failure.
The gas dryer installation must meet the American National Standard...National Fuel Gas Code ANSI Z223.1-
LATEST EDITION, or in Canada, the Canadian Installation Codes CAN/CGA-B149.1 M91 (Natural Gas) or
CAN/CGA-B149.2-M91 (Liquid Propane [L.P.] Gas) or LATEST EDITION, as well as local codes and ordinances
and must be done by a qualified professional.
NOTE: Undersized gas piping will result in ignition problems and slow drying and can create a safety
hazard.
The dryer must be connected to the type of gas (natural or L.P.) indicated on the dryer data label. If this
information does not agree with the type of gas available, contact the reseller who sold the dryer or contact the
factory.
The gas input ratings shown on the dryer data label are for elevations up to 2,000 feet (609.6 meters), unless
elevation requirements of over 2,000 feet (609.6 meters) were specified at the time the dryer order was placed
with the factory. The adjustment for dryers in the field for elevations over 2,000 feet (609.9 meters) is made by
changing the burner orifices. If this adjustment is necessary, contact the reseller who sold the dryer or contact
the factory.
NOTE: Any burner changes must be made by a qualified technician.
C. OPERATIONAL SERVICE CHECK PROCEDURE
After performing any service or maintenance function, an operational check should be performed to insure that
ALL components are performing properly.
1. Make a complete operational check of ALL the operating controls to insure that the timing is correct,
temperature selection switches are functioning properly.
2. Make a complete operational check of ALL safety related circuits, door switches, hi-limit thermostat, sail
switch, cycling thermostats, etc.
14
SECTION V
COMPONENT DESCRIPTION/REPLACEMENT
A. HEAT SECTION
The dryer uses three (3) types of heat sources: natural gas, liquid propane (L.P.) gas, and steam. Natural gas and
L.P. gas are not directly replaceable. The gas valves need to be modified to use other than the type of heat
specified on the nameplate.
1. Gas dryers utilize a Direct Spark Ignition (DSI) module to monitor that a flame is established. If for some
reason the flame signal is lost, the DSI module will shut off the gas valve and not retry ignition (no try to
restart the flame). A spark of approximately 14,000 volts is used to establish a flame. The DSI module will
turn the gas valve on and ignitor/flame-probe will spark for 8-seconds attempting a flame. Each time the
dryer calls for heat the microprocessor controller (computer) will send a 24 VAC signal through the exhaust
hi-limit, sail switch, and oven hi-limit. At that point, the DSI module will try for ignition.
DSI SYSTEM COMPONENTS/FUNCTIONS
Johnson (DSI) Control Module P/N 128935
ADC (DSI) Control Module P/N 128973
15
Johnson (DSI) Control Module
P/N 128935
a. The Direct Spark Ignition
(DSI) Module is a 24 VAC
device designed to be the
“controller” of the DSI system.
When activated by the dryer
controls, this module constantly
monitors and controls the
functions of the DSI system
(i.e., spark activation, gas valve
off and on, flame verification,
etc.). Additionally, the DSI
Module has self-diagnostic
capabilities.
24 VAC Direct Spark Ignition (DSI) Module
b. The Ignitor/Flame-Probe Assembly is located in the burner
flame area and is used to ignite the gas by use of a high voltage
(HV) spark (approximately 14,000 volts) and to provide
feedback information to the DSI Module as to whether the
burner flame is evident (on).
ADC (DSI) Control Module
P/N 128973
c. The Manual Reset Burner Hi-Limit Switch is a thermostat
type switch located in the burner. Its function is to discontinue
heat (flame) in the event of an over temperature situation (above
330º F [166º C]). The hi-limit must be manually reset once
the device tripped.
d. The Sail Switch Assembly is located on the Burner Assembly,
downstream of the flame tubes. Its function is to detect whether
or not there is sufficient airflow through the dryer.
Ignitor/Flame-Probe Assembly
MAN3484
330º F (166º C) Thermostat
16
Sail Switch Assembly
e. The Manual Reset Basket (Tumbler) Hi-Limit Switch is a
thermostat type switch located above the Lint Basket. Its function
is to discontinue heat (flame) in the event of an over temperature
situation (above 225º F [107º C]).
f. The gas valve used in the ADG-200 is of the redundant type
which means that the gas valve is actually two (2) gas valves in
one (1); one (1) in series with the other. This is a safety
feature, which provides protection against gas flow in the event
that one (1) of the valves does not seat properly. The valve also
regulates the incoming gas pressure.
MAN3484
225º F (107º C) Thermostat
NOTE: THE DSI GAS VALVES ARE NOT FIELD
Redundant Gas Valve
REPAIRABLE.
g. Normal Operation of the Direct Spark Ignition (DSI) System (refer to the illustration on page 15).
1) The DSI System consists of a microprocessor-based control module, along with an Ignitor/FlameProbe Assembly. This control utilizes a high voltage (HV) synchronous spark ignitor and a rectified
flame sensor probe signal to locally control ALL basic functions in the gas burner.
On a call for heat by the dryers’ controls, 24 VAC is applied to the DSI module at which time the
modules’ light emitting diode (L.E.D.) indicator will light “red” indicating that power has been established
to the module. Almost immediately (up to approximately 1.5-seconds [prepurge]) the indicator will
light “green,” the gas valve opens and the spark burst will be evident (on) for approximately
8-seconds. The burner flame should now be established/confirmed.
If at this time the flame has not been established and confirmed, the DSI module will “LOCKOUT”
and the modules’ L.E.D. indicator will light “red” and stay on continuously. “Burner Ignition Control
Fault” will display. To clear this fault press the “CLEAR/STOP” key.
Once the burner flame is established and confirmed, the DSI module indicator will light “green,” and
the burner system will continue through a normal heating cycle, where the DSI system will cycle on
and off as required by the dryer’s controls.
During the normal heating cycle, should a “FLAMEOUT” occur (i.e., severe air turbulence forces
the flame away from the Ignitor/Flame-Probe Assembly), the DSI module will shut the gas valve off
and immediately try to reestablish the burner flame. The DSI module will attempt to light the
burner ONLY ONCE. If flame is not established, the DSI module will “LOCKOUT” and “Burner
Ignition Control Fault” will display. To clear this fault press the “CLEAR/STOP” key.
17
h. Troubleshooting Flowchart - Quick Reference...
First Visual Check
No Spark And System Does Not Work
Is 24 VAC available
at transformer?
No Yes
Is power available
to primary?
No Yes
Determine why
voltage is not
present.
Replace
Transformer.
Are thermostat contacts and
Close
Contacts.
Check continuity of wiring to
determine why voltage does
limit control contacts closed?
No Yes
not exist at THS2.
Install
Jumper.
Is 24 VAC present from terminal
THS2 to ground?
No Yes
Is jumper installed
from terminal 5 to
ground?
No Yes
Turn off supply voltage.
Check high voltage cable.
Is it securely attached to
spark transformer?
No Yes
Correct
Johnson Control
module G760/761
Open thermostat contacts for 30 seconds.
Close contacts and wait for prepurge (if applicable)
period. Is spark present now?
No Yes
Is condition of high voltage
cable good (not brittle,
burnt, or cracked)?
No Yes
Replace
Is spark electrode
ceramic cracked
or is electrode
Replace
grounded out?
No Yes
Replace electrode
assembly.
18
System was in lockout.
Observe a complete operating
cycle to determine why
control locked out.
i. Troubleshooting Flowchart - Quick Reference...
Second Visual Check
Spark Present But Main Burner Does Not Come On
Is main valve wiring securely
attached to terminal M.V.3
and ground?
No Yes
Correct
Replace
Johnson Control
module G760/761
Determine
why continuity
does not exist.
Is 24 VAC present
between terminals M.V.3
No Yes
and ground ?
Check for continuity in
wiring from M.V.3 to gas
valve, and gas valve to GR.
No Yes
Correct
Correct
Is inlet gas pressure per
manufacturer's specifications?
No Yes
Is Spark gap .125 in.
and in gas stream?
No Yes
Replace
gas valve.
19
j. Troubleshooting Flowchart - Quick Reference...
Third Visual Check
Main Burner Lights But Will Not Stay On
Is flame sensor cable
securely attached
to terminal 4?
No Yes
Correct
Replace
sensor
cable.
Correct or
replace
sensor.
Does continuity exist
to flame sensor?
No Yes
from control
Is flame sensor corroded
or is ceramic cracked?
No Yes
Correct
Is flame sensor
positioned per
manufacturer's specifications?
No Yes
Correct
Replace
Johnson Control
module
G760/761
Does continuity exist in
ground path from burner
to control?
No Yes
Check flame sensing current
during trial. Is current
greater than 0.3µ A DC?
No Yes
Replace
Johnson Control
module
G760/761
20
B. TROUBLESHOOTING THE DIRECT SPARK IGNITION (DSI) SYSTEM
NOTE: The troubleshooting information provided in this manual is intended for use by qualified service
technicians only. OBSERVE ALL SAFETY PRECAUTIONS displayed on the equipment
or specified in the AD-200 Phase 7 Non-Tilting Installation/Operator’s Manual (ADC Part
No. 112142) included with the dryer.
IMPORTANT: UNDER NO CIRCUMSTANCES SHOULD ANY SAFETY OR HEAT
CIRCUIT DEVICES EVER BE DISABLED.
THE FOLLOWING PIECES OF TEST EQUIPMENT WILL BE REQUIRED TO
TROUBLESHOOT THIS SYSTEM WITH MINIMAL TIME AND EFFORT
MANOMETER
Used To Measure Gas Pressure In Inches
Of Water Column (W.C.)
DSI IGNITOR GAP FEELER GAUGE
(1/8” [3.175 mm])
Used For Checking Gap Between Ignitor/
Flame-Probe Assembly and Spark Electrode
Available From ADC
MULTIMETER/VOLTMETER
For Measuring Voltage
Available From ADC
21
1. Direct Spark Ignition (DSI) Troubleshooting Terms (definitions) ADC (DSI) Control Module P/N 128973
a. DSI MODULE “RED” L.E.D. INDICATOR LIGHT - This “red” light emitting diode (L.E.D.) light is
located in the upper right corner of the DSI
module (refer to the top illustration on page
16). This is a diagnostic indicator that simplifies
the operational and troubleshooting procedures
of the DSI system.
b. LOCKOUT MODE - DSI module “red” L.E.D. indicator light stays on continuously. This indicates
there is a system fault and most likely, the fault is the DSI module itself.
c. FLAMEOUT - Burner flame shutdown by the DSI module due to lack of flame verification. This
condition occurs only after ignition is evident but is lost. The DSI system will immediately
attempt to relight the burner.
d. RECYCLE - Flame has been sensed but lost. Initiate a new sequence (THERE ARE NO RETRIES).
2. Troubleshooting and System Basic Diagnosis ADC (DSI) Control Module P/N 128973
a. Preliminary Steps
The following steps must be performed to
minimize the time required to isolate cause of fault.
1) DSI module L.E.D. indicator light is off (no
“red” or “green” light).
a) Check for voltage (approximately 24
VAC) across the DSI model terminals
“TH” and “GND”...
If voltage (approximately 24 VAC) is
evident, then, there is a malfunction within
the DSI module itself, and it must be
replaced.
If there is no voltage present, then problem is not the DSI module or the ignition system, the
problem is elsewhere in the dryer (i.e., dryer’s heat circuit [sail switch, hi-limit circuits, etc.]).
2) DSI module L.E.D. indicator lights “red” for approximately 1.5-seconds (prepurge). This indicates
that ALL the controls (including ALL the safety circuits) are functioning and power is being supplied
to the DSI module.
3) DSI module L.E.D. indicator lights “green.” This indicates a normal heating cycle. This also
indicates that the preliminary diagnostics of the module has confirmed that the DSI module is functional.
4) DSI module L.E.D. indicator lights “red” continuously...“LOCKOUT” mode. This indicates that
there is a system fault and most likely the fault is internal to the DSI module. To make sure, open
and close the main door. Restart the dryer...if the module LOCKS OUT (“red” L.E.D. indicator
light stays on continuously) again, replace the DSI module.
22
If the dryer repeatedly has Direct Spark Ignition (DSI) module “LOCKOUT” failures, the cause
may be due to high voltage (HV) not getting into the DSI module ignitor probe assembly.
5) Check to insure that the red high voltage wire (between the ignitor spark electrode and the DSI
module) is not wrapped around the sensor probe wire (the wire between the DSI module FP
terminal and the Ignitor/Flame-Probe Assembly). If the wires are touching one another, separate
and secure in place AWAY FROM ONE ANOTHER.
6) Check to insure that the dryer is properly grounded and that the ground connections (GND) to the
DSI module are secure.
7) If the problem persists, it is most likely to be in the external components (not the DSI module), or
wiring, due to a “FLAMEOUT”...proceed as follows:
NOTE: Preliminary steps - DO NOT omit - to minimize the time required to troubleshoot this system.
a) Disconnect the electrical power to the dryer.
b) Visually, check the DSI module components for visual damage.
c) Check wiring for loose connections, nicks, cracking at the ceramic insulator, or shorting of the
sensor to the burner.
d) Inspect the DSI Ignitor/Flame-Probe Assembly...
...Check electrode for visible cracking at the ceramic insulator or shorting of sensor to burner
...Check to insure that the flame sensor rod is positioned over the flame area
...Check for carbon deposits on the flame sensor rod
...Check to insure that there is a 1/8” +/- 1/32” (3.175 mm +/- 0.79248 mm) gap between the
ground rod and the ignitor spark electrode
b. After performing these inspections and making corrections - if any - restore power to the dryer...start
the dryer and operate through one (1) complete cycle to insure that ALL components are functioning
properly. If a no heat condition persists, refer to the Troubleshooting Flowcharts on page 25, page
26, and page 27.
1) To effectively use this information or the flowcharts, each step must be completed in sequence,
performing whatever tests are suggested. After the completion of each test, the guide will direct the
Service Technician to the next logical step in the troubleshoot sequence based on the outcome of the
previous check.
2) Components should be replaced only after each step has been completed and replacements after
each step has been completed and replacement is suggested in the flowchart. However, the
experienced technician realizes that a loose connection or broken or shorted wire may be at fault
where electrical components are concerned...and not necessarily the suspected component itself.
23
c. Three (3) Visual Checks
1) Does the Direct Spark Ignition (DSI) Ignitor/Flame-Probe Assembly start sparking?
If not, refer to the FIRST VISUAL CHECK on page 25.
2) Does the main burner ignite?
If not, refer to the SECOND VISUAL CHECK on page 26.
3) Does the main burner remain lit after ignition has been established (“FLAMEOUT”)?
If not, refer to the THIRD VISUAL CHECK on page 27.
24
d. Troubleshooting Flowchart - Quick Reference...
First Visual Check
(Does Ignitor Spark?)
Computer/Timer Calls For Heat
I
s spark evident (on)
at Ignitor Assembly?
Yes
Go To Chart 2
No
Is 24 Volts
present across DSI Module
terminals
TH and COM?
Yes
Check
High Voltage (HV)
Lead for nicks or cracking,
where sparking to ground may
occur. Is this wire
damaged?
No
Visually
inspect Spark
Electrode Assembly. Is
ceramic cracked or Spark
Electrode incorrectly
gapped?
No
Yes
Yes
Open circuit to DSI System.
Check the 24 VAC power source
Sail Switch and Hi-Limit
Repair or replace HV Lead
Assembly.
Energize system and check
for proper operation.
If cracked, replace Electrode
Assembly. Correct gap size
is 1/8" (+/- 1/32").
Energize system and check
for proper operation.
.
Replace the DSI Module.
Energize system and check
for proper operation.
No
Visually
inspect High
Voltage (HV) Wire
connections at both DSI Module
and Ignitor Assembly.
Are connections
secure?
Yes
Remove
High Voltage
(HV) Wire from
DSI Module and visually
inspect. Is conductor
visible at end of
HV Wire?
25
1. At DSI Ignitor Assembly be
sure HV Wire is secure in
the boot as well as the
connection to the Ignitor
No
NoYes
Probe Assembly.
2. At DSI Module, center the
end of the HV Wire with a
Spike Terminal. Energize
system and check for
proper operation.
Cut the end off of the HV Wire
1/4" at a time until conductor
becomes visible and is flush
with the insulation.
Reconnect the HV Wire to the
Spike Terminal on the DSI
Module.
Energize system and check
for proper operation.
e. Troubleshooting Flowchart - Quick Reference...
Second Visual Check
(Does Main Burner Ignite?)
Does
main burner
light?
Yes Yes
Go To
Third Visual
Check
Restore gas supply.
Energize system and
check for proper
operation.
No
gas available
at the
source?
Turn knob to “ON/OPEN”
position.
Energize system and
check for proper operation.
No
Is manual
knob on the Gas Valve
in the “ON”
position?
No
Is
dryer Internal Gas
Shut-Off Valve and
ALL
External Gas Shut-Off
No
Valves in the open
position?
Yes
Turn manual knob on the Gas Valve to the
“OFF” position.
Connect a manometer to the Gas Valve
Correct supply pressure.
Energize system and
check for proper operation
.
outlet pressure tap.
No
Turn
Is
No
manual knob on
the Gas Valve to the
“ON” position.
Yes
Energize the system.
Is outlet pressure
detected?
Is outlet
Water Column (W.C.)
pressure correct?
Natural 3.5” - 4.0” W.C.
(8.7 mb - 9.9 mb)
L.P. 10.5” - 11.0” W.C.
(26.1 mb - 27.4 mb)
Yes
Energize
system. Is 24 VAC
present across leads
at the Gas
Valve?
Yes
Replace the Gas Valve.
Energize the system and
check for proper operation.
No
With
system energized,
is 24 VAC present
across the “MV” and “GND”
terminals of the DSI
Module?
Yes
Replace High
Voltage (HV)
leads
Energize system
and check for
proper operation.
26
No
Replace
DSI Module
Yes
Check Spark Electrode for
proper gap and insure that
the spark is in the path of
the gas flow...
Refer To Service Section.
Make the necessary
corrections.
Energize system and
check for proper operation.
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